Additive manufacturing method for building three-dimensional objects with core-shell arrangements, and three-dimensional objects thereof

ABSTRACT

A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a divisional of U.S. patent application Ser. No.13/419,669, filed on Mar. 14, 2012, and entitled “Core-Shell ConsumableMaterials For Use In Extrusion-Based Additive Manufacturing Systems”;which is a continuation-in-part of U.S. patent application Ser. No.13/233,280, filed on Sep. 15, 2011, and entitled “Semi-CrystallineConsumable Materials For Use In Extrusion-Based Additive ManufacturingSystems; which claims priority to U.S. Provisional Patent ApplicationNo. 61/383,844, filed on Sep. 17, 2010, and entitled “Semi-CrystallineConsumable Materials For Use In Extrusion-Based Additive ManufacturingSystems”.

BACKGROUND

The present disclosure is directed to additive manufacturing systems forbuilding three-dimensional (3D) models. In particular, the presentdisclosure relates to consumable materials for use in extrusion-basedadditive manufacturing systems.

An extrusion-based additive manufacturing system is used to build a 3Dmodel from a digital representation of the 3D model in a layer-by-layermanner by extruding a flowable modeling material. The modeling materialis extruded through an extrusion tip carried by an extrusion head, andis deposited as a sequence of roads on a substrate in an x-y plane. Theextruded modeling material fuses to previously deposited modelingmaterial, and solidifies upon a drop in temperature. The position of theextrusion head relative to the substrate is then incremented along az-axis (perpendicular to the x-y plane), and the process is thenrepeated to form a 3D model resembling the digital representation.

Movement of the extrusion head with respect to the substrate isperformed under computer control, in accordance with build data thatrepresents the 3D model. The build data is obtained by initially slicingthe digital representation of the 3D model into multiple horizontallysliced layers. Then, for each sliced layer, the host computer generatesa build path for depositing roads of modeling material to form the 3Dmodel.

In fabricating 3D models by depositing layers of a modeling material,supporting layers or structures are typically built underneathoverhanging portions or in cavities of objects under construction, whichare not supported by the modeling material itself. A support structuremay be built utilizing the same deposition techniques by which themodeling material is deposited. The host computer generates additionalgeometry acting as a support structure for the overhanging or free-spacesegments of the 3D model being formed. Support material is thendeposited from a second nozzle pursuant to the generated geometry duringthe build process. The support material adheres to the modeling materialduring fabrication, and is removable from the completed 3D model whenthe build process is complete.

SUMMARY

A first aspect of the present disclosure is directed to a 3D objectbuilt with an extrusion-based additive manufacturing system. The 3Dobject includes a plurality of solidified layers each comprising roadsformed from a flowable consumable material that exits an extrusion tipof the extrusion-based additive manufacturing system, where the flowableconsumable material exiting the extrusion tip comprises a core materialand a shell material that is compositionally different from the corematerial, and where the shell material at least partially encases thecore material to provide an interface between the core material and theshell material. At least a portion of the roads of the plurality ofsolidified layers comprise core regions of the core material and shellregions of the shell material, where the core regions and the shellregions substantially retain cross-sectional profiles corresponding tothe interface between the core material and the shell material of theflow able consumable material.

Another aspect of the present disclosure is directed to a method forbuilding a 3D object with an additive manufacturing system having anextrusion head. The method includes extruding a flowable consumablematerial from an extrusion tip of the extrusion head, where the flowableconsumable material comprises a core material and a shell material thatis compositionally different from the core material, and where the shellmaterial at least partially encases the core material to provide aninterface between the core material and the shell material. The methodalso includes depositing the flowable consumable material as extrudedroads that define layers of the 3D object, and solidifying the extrudedroads. The solidified roads have core regions of the core material andshell regions of the shell material, where the core regions and theshell regions substantially retain cross-sectional profilescorresponding to the interface between the core material and the shellmaterial of the flowable consumable material.

Another aspect of the present disclosure is directed to a method forbuilding a 3D object with an additive manufacturing system having anextrusion head, which includes extruding a flowable consumable materialfrom an extrusion tip of the extrusion head, where the flowableconsumable material includes a thermoplastic core material and a shellmaterial that is a different color from that of the thermoplastic corematerial, and where the shell material at least partially encases thethermoplastic core material to provide an interface between thethermoplastic core material and the shell material. The method alsoincludes depositing the flowable consumable material as extruded roadsthat define layers of the 3D object, and solidifying the extruded roads,wherein the solidified roads have core regions of the thermoplastic corematerial and shell regions of the shell material such that exteriorsurfaces of the solidified roads have the color of the shell material.

DEFINITIONS

Unless otherwise specified, the following terms used in thisspecification have the meanings provided below.

The term “semi-crystalline polymeric material” refers to a materialcomprising a polymer, where the polymer is capable of exhibiting anaverage percent crystallinity in a solid state of at least about 10% byweight. The term “semi-crystalline polymeric material” includespolymeric materials having crystallinities up to 100% (i.e.,fully-crystalline polymeric materials). For ease of discussion, the term“semi-crystalline polymeric material” is used herein since mostpolymeric materials have at least a small number of amorphous regions.

The terms “percent crystallinity”, “peak crystallization temperature”,“slope-intercept crystallization temperature”, “peak meltingtemperature”, and “slope-intercet melting temperature” are defined belowin the specification with reference to differential scanning calorimetry(DSC) plots and ASTM D3418-08.

The terms “core portion” and “shell portion” of a filament refer torelative locations of the portions along a cross-section of the filamentthat is orthogonal to a longitudinal length of the filament, where thecore portion is an inner portion relative to the shell portion. Unlessotherwise stated, these terms are not intended to imply any furtherlimitations on the cross-sectional characteristics of the portions.

The term “three-dimensional object” refers to any object built using alayer-based additive manufacturing technique, and includes 3D models andsupport structures built using layer-based additive manufacturingtechniques.

The terms “about” and “substantially” are used herein with respect tomeasurable values and ranges due to expected variations known to thoseskilled in the art (e.g., limitations and variabilities inmeasurements).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of an extrusion-based additive manufacturingsystem for building 3D models with the use of consumable materials ofthe present disclosure.

FIG. 2 is a perspective view of a segment of a consumable filament ofthe present disclosure, where the consumable filament includes a coreportion and a shell portion.

FIG. 3 is an illustrative differential scanning calorimetry plot of heatflow versus temperature during a cooling phase for a shell material ofthe shell portion.

FIG. 4 is an illustrative differential scanning calorimetry plot of heatflow versus temperature during a cooling phase for a core material ofthe core portion.

FIG. 5 is a side illustration of layers of a 3D model during a buildoperation, where the dimensions of the layers and the relative distanceof an extrusion tip from the layers are exaggerated for ease ofdiscussion.

FIG. 6 is a perspective view of a segment of an alternative consumablefilament of the present disclosure, where the alternative consumablefilament includes a core portion and a shell portion, where the shellportion is defined by an inner shell and outer shell.

FIG. 7 is a perspective view of a segment of a second alternativeconsumable filament of the present disclosure, where the secondalternative consumable filament includes a rectangular cross-sectionalgeometry.

FIG. 8 is a perspective view of a segment of a third alternativeconsumable filament of the present disclosure.

FIG. 9 is a side illustration of model layers and support layers, wherethe support layers are formed from the third alternative consumablefilament, and where the dimensions of the layers are exaggerated forease of discussion.

FIGS. 10A-10C are side illustrations of a technique for removing thesupport layers from the model layers.

FIGS. 11 and 12 are photographs of cross-sectional segments of examplesemi-crystalline filaments of the present disclosure.

FIG. 13 is a differential scanning calorimetry plot of heat flow versustemperature for a shell material of the example semi-crystallinefilaments.

FIG. 14 is a differential scanning calorimetry plot of heat flow versustemperature for a core material of the example semi-crystallinefilaments.

FIGS. 15 and 16 are photographs of 3D models built with a first examplesemi-crystalline filament of the present disclosure.

FIGS. 17 is a photograph of cross-sectional profiles of extruded andsolidified layers of a 3D model built with the first examplesemi-crystalline filament of the present disclosure.

FIG. 18 is an expanded view photograph of cross-sectional profiles shownin FIG. 17.

FIGS. 19-22 are photographs of 3D models built with a second examplesemi-crystalline filament of the present disclosure.

DETAILED DESCRIPTION

The present disclosure is directed to consumable materials (e.g.,consumable filaments) for use in extrusion-based additive manufacturingsystems, where the consumable materials have core-shell arrangements.The core-shell arrangements include a core portion and a shell portion(or multiple core and/or shell portions), where the core portion and theshell portion compositionally include different materials that impartdifferent properties for the consumable materials. In particular, thecore portion compositionally includes a first thermoplastic material andthe shell portion compositionally includes a second thermoplasticmaterial that is different from the first thermoplastic material. Asdiscussed below, the different properties from these materials mayassist in the build operations in the extrusion-based additivemanufacturing systems.

FIGS. 1-7 illustrate a first embodiment of the consumable materials ofthe present disclosure. In this embodiment, the consumable materialscompositionally include multiple semi-crystalline polymeric materialshaving different crystallization temperatures. As discussed below, thisdifference in crystallization temperatures desirably reducesdistortions, internal stresses, and sagging of the semi-crystallinepolymeric materials when deposited as extruded roads to form layers of3D models. The resulting 3D models may accordingly be built with reducedlevels of curling and distortion, with good dimensional accuracies, andwith good interlayer z-bond strengths.

Extrusion-based additive manufacturing systems currently build 3D modelswith the use of amorphous polymeric materials, such asacrylonitrile-butadiene-styrene (ABS) resins and polycarbonate resins.Amorphous polymeric materials have little or no ordered arrangements oftheir polymer chains in their solid states. As such, these materialsexhibit glass transition effects that render them suitable for building3D models and support structures in extrusion-based additivemanufacturing systems. For example, as disclosed in Batchelder, U.S.Pat. No. 5,866,058, an amorphous polymeric material may be depositedinto a build region maintained at a temperature that is between asolidification temperature and a glass transition temperature of thematerial. This reduces the effects of curling and plastic deformation inthe resulting 3D model or support structure.

Semi-crystalline polymeric materials, however, have different mechanicaland thermal characteristics from amorphous polymeric materials. Forexample, due to their crystallinity, 3D models built withsemi-crystalline polymeric materials may exhibit superior mechanicalproperties compared to 3D models built with amorphous polymericmaterials. However, due to their higher levels of crystallinity,semi-crystalline polymeric materials exhibit discontinuous changes involume upon solidification. Therefore, when supplied as a monofilament,a semi-crystalline polymeric material may contract and shrink whendeposited to form a 3D model in an extrusion-based additivemanufacturing system. This is particularly true for materials that arehighly crystalline in their solid states.

This shrinkage initially occurs when an extruded road is deposited toform a portion of a layer of a 3D model. Additional shrinkage alsooccurs upon further cooling of the 3D model. These shrinkages can causecumulative distortions, internal stresses, and curling of the 3D modelbeing fabricated. For amorphous polymeric materials, curling anddistortion can be reduced by elevating the temperature in the buildregion. However, for semi-crystalline polymeric materials, which exhibitdiscontinuous changes in volume upon solidification, the elevatedtemperature required to reduce distortions results in sagging of theextruded roads, which may also result in distortions of the 3D modelbeing built.

Accordingly, in one embodiment, the consumable materials of the presentdisclosure include a consumable, semi-crystalline filament having afirst or core portion and a second or shell portion, where the first andsecond portions are derived from semi-crystalline polymeric materialshaving different crystallization temperatures. As discussed below, thisdifference in crystallization temperatures allows the material of thesecond portion to crystallize upon deposition, while the material of thefirst portion crystallizes upon further cooling. This desirably reducesdistortions, internal stresses, and sagging of the semi-crystallinepolymeric materials when deposited as extruded roads to form layers of3D models.

As shown in FIG. 1, system 10 is an extrusion-based additivemanufacturing system for building 3D models with a semi-crystallinefilament. As such, the resulting 3D models may be built withsemi-crystalline polymeric materials, while exhibiting reduceddistortions. Examples of suitable systems for system 10 includeextrusion-based additive manufacturing systems, such as thosecommercially available from Stratasys, Inc., Eden Prairie, Minn. underthe trade designations “FUSED DEPOSITION MODELING” and “FDM”.

System 10 includes build chamber 12, platen 14, gantry 16, extrusionhead 18, and supply sources 20 and 22. Build chamber 12 is an enclosed,heatable environment that contains platen 14, gantry 16, and extrusionhead 18 for building a 3D model (referred to as 3D model 24) and acorresponding support structure (referred to as support structure 26).Platen 14 is a platform on which 3D model 24 and support structure 26are built, and desirably moves along a vertical z-axis based on signalsprovided from computer-operated controller 28. Platen 14 may alsoinclude a polymeric film (not shown) to further facilitate the removalof 3D model 24 and support structure 26.

Gantry 16 is a guide rail system that is desirably configured to moveextrusion head 18 in a horizontal x-y plane within build chamber 12based on signals provided from controller 28. The horizontal x-y planeis a plane defined by an x-axis and a y-axis (not shown), where thex-axis, the y-axis, and the z-axis are orthogonal to each other. In analternative embodiment, platen 14 may be configured to move in thehorizontal x-y plane within build chamber 12, and extrusion head 18 maybe configured to move along the z-axis. Other similar arrangements mayalso be used such that one or both of platen 14 and extrusion head 18are moveable relative to each other.

Extrusion head 18 is supported by gantry 16 for building 3D model 24 andsupport structure 26 on platen 14 in a layer-by-layer manner, based onsignals provided from controller 28. In the embodiment shown in FIG. 1,extrusion head 18 is a dual-tip extrusion head configured to depositmaterials from supply source 20 and supply source 22, respectively.Examples of suitable extrusion heads for extrusion head 18 include thosedisclosed in Crump et al., U.S. Pat. No. 5,503,785; Swanson et al., U.S.Pat. No. 6,004,124; LaBossiere, et al., U.S. Pat. No. 7,604,470; andLeavitt, U.S. Pat. No. 7,625,200. Furthermore, system 10 may include aplurality of extrusion heads 18 for depositing modeling and/or supportmaterials.

The semi-crystalline filament may be used as the modeling material forbuilding 3D model 24. As such, the semi-crystalline filament may besupplied to extrusion head 18 from supply source 20 via feed line 30,thereby allowing extrusion head 18 to melt and deposit thesemi-crystalline polymeric materials as a series of extruded roads tobuild 3D model 24 in a layer-by-layer manner. Correspondingly, thesupport material may be supplied to extrusion head 18 from supply source22 via feed line 32, thereby allowing extrusion head 18 to melt anddeposit the support material as a series of extruded roads to buildsupport structure 26 in a layer-by-layer manner. Suitable devices forsupply sources 20 and 22 include those disclosed in Swanson et al., U.S.Pat. No. 6,923,634; Comb et al., U.S. Pat. No. 7,122,246; and Taatjes etal, U.S. Patent Application Publication Nos. 2010/0096485 and2010/0096489.

In one embodiment, the support material used to build support structure26 may be an amorphous polymeric material, such as the water-soluble andbreak-away support materials commercially available from Stratasys,Inc., Eden Prairie, Minn. In an alternative embodiment, asemi-crystalline filament of the present disclosure may also be used asthe support material for building support structure 26. As such, in thisalternative embodiment, support structure 26 may also be built usingsemi-crystalline polymeric materials.

During a build operation, gantry 16 moves extrusion head 18 around inthe horizontal x-y plane within build chamber 12, and one or more drivemechanisms are directed to intermittently feed the modeling and supportmaterials through extrusion head 18 from supply sources 20 and 22.Examples of suitable drive mechanisms for use in extrusion head 18include those disclosed in Crump et al., U.S. Pat. No. 5,503,785;Swanson et al., U.S. Pat. No. 6,004,124; LaBossiere, et al., U.S. Pat.Nos. 7,384,255 and 7,604,470; Leavitt, U.S. Pat. No. 7,625,200; andBatchelder et al., U.S. Patent Application Publication No. 2009/0274540.

The received modeling and support materials are then deposited ontoplaten 14 to build 3D model 24 and support structure 26 as extrudedroads using a layer-based additive manufacturing technique. Buildchamber 12 is desirably heated to one or more suitable temperatures toallow the extruded roads of 3D model 24 to crystallize in two stages. Inparticular, the temperature(s) of build chamber 12 desirably allow thesemi-crystalline polymeric material of the second or shell portion tocrystallize upon deposition, while the semi-crystalline polymericmaterial of the first or core portion desirably crystallizes uponfurther cooling. This allows the extruded roads to resist gravity andthe pressures of subsequent layers, while also reducing distortions of3D model 24.

Support structure 26 is desirably deposited to provide vertical supportalong the z-axis for overhanging regions of the layers of 3D model 24.This allows 3D object 24 to be built with a variety of geometries. Afterthe build operation is complete, the resulting 3D model 24/supportstructure 26 may be removed from build chamber 12. Support structure 26may then be removed from 3D model 24. For example, in embodiments inwhich the support material is water soluble, the resulting 3D model24/support structure 26 may be placed in a bath containing an aqueousliquid and/or solution (e.g., an aqueous alkaline solution) to removesupport structure 26 from 3D model 24.

FIG. 2 illustrates a segment of filament 34, which is an example of asuitable consumable, semi-crystalline filament of the presentdisclosure. As shown, filament 34 includes core portion 36 and shellportion 38, which extend along longitudinal length 40. Core portion 36is the inner portion of filament 34, located around central axis 42, andshell portion 38 is the outer portion of filament 34, located adjacentto outer surface 44. Core portion 36 compositionally includes a firstsemi-crystalline polymeric material, referred to as a core material.Shell portion 38 compositionally includes a second semi-crystallinepolymeric material, referred to as a shell material, where the shellmaterial has a higher crystallization temperature than the corematerial.

The core and shell materials each include one or more base polymers and,optionally, one or more additives to modify the crystallizationtemperatures of the base polymers. Examples of suitable base polymersfor use in each of the core and shell materials include polyamides,polyethylenes, polypropylenes, polyetheretherketones,polyetherarylketones, perfluoroalkoxys, polychlorotrifluoroethylenes,polyphenylene sulfides, fluorinated ethylene propylenes,polytetrafluoroethylenes, ethylene-tetrafluoroethylenes, polyvinylidenefluorides, and ethylene-chlorortifluoroethylenes, copolymers thereof,and combinations thereof. Suitable polyamides include aliphatic nylonpolyamides, such as nylon 6, nylon 6-6, nylon 6-10, nylon 6-12, nylon10, nylon 10-10, nylon 11, nylon 12, and combinations thereof. Suitablepolyethylenes include low-density polyethylene, medium-densitypolyethylene, high-density polyethylene, and combinations thereof.Suitable polypropylenes include isotactic polypropylenes, syndiotacticpolypropylenes, branched and linear variations thereof, and combinationsthereof. Unless indicated otherwise, the base polymers for the core andshell materials are not intended to be limited to these listed polymers.

As defined above, the base polymers for the core and shell materials areeach capable of achieving an average percent crystallinity in a solidstate of at least about 10% by weight. In one embodiment, the basepolymer(s) for the core material and/or the shell material is capable ofachieving an average percent crystallinity in a solid state of at leastabout 25% by weight. In another embodiment, the base polymer(s) for thecore material and/or the shell material is capable of achieving anaverage percent crystallinity in a solid state of at least about 50% byweight. The term “percent crystallinity” is defined below with referenceto a differential scanning calorimetry (DSC) plot and ASTM D3418-08 .

The difference in crystallization temperatures between the core andshell materials may be attained with a variety of different materialcombinations. In one embodiment, the core and shell materials includedifferent base polymers to attain different crystallizationtemperatures. For example, core portion 36 may be derived frompolyethylene, and shell portion 38 maybe derived from an isotacticpolypropylene having a crystallization temperature greater than that ofthe polyethylene of core portion 36.

In another embodiment, the core and shell materials may include basepolymers derived from the same or similar monomer units, but havedifferent molecular properties to produce different crystallizationtemperatures, such as different relative molar masses, differentmolecular weights, different terminal group chemistries, differentstereochemistries, and combinations thereof. For example, core portion36 may be derived from a highly-branched isotactic polypropylene, andshell portion 38 maybe derived from a linear isotactic polypropylene.

In yet another embodiment, the core and shell materials may include thesame or similar base polymers, where the core material also includes oneor more additives to decrease its crystallization temperature. Forexample, the shell material may include a base polymer (e.g., nylon-12polyamide), and the core material may include the same or similar basepolymer (e.g., nylon-12 polyamide) and one or more crystallizationinhibitors to decrease the crystallization temperature of the corematerial relative to the shell material.

Crystallization inhibitors may slow down the crystal growth of the basepolymer in the core material by blocking growth sites on the crystalsurfaces. Examples of suitable crystallization inhibitors for use in thecore material include polyether block amide (PEBA) copolymers, and thelike. The crystallization inhibitors may be blended with the basepolymer and/or incorporated in the backbone of the base polymer.

Examples of suitable concentrations of crystallization inhibitors in thecore material range from about 0.1% by weight to about 20% by weight. Inone embodiment, suitable concentrations of crystallization inhibitors inthe core material range from about 0.5% by weight to about 15% byweight. In yet another embodiment, suitable concentrations ofcrystallization inhibitors in the core material range from about 1% byweight to about 10% by weight.

In an additional embodiment, the core and shell materials may includethe same or similar base polymers, where the shell material alsoincludes one or more additives to increase its crystallizationtemperature. For example, the core material may include a base polymer(e.g., nylon-12 polyamide), and the shell material may include the sameor similar base polymer (e.g., nylon-12 polyamide) and one or morenucleating agents to increase the crystallization temperature of theshell material relative to the core material.

The nucleating agents may increase the nucleation rate of the basepolymer in the shell material, thereby providing higher crystallinityand smaller crystals. This may also render the shell material moretransparent to visible light. As such, in some embodiments, thenucleating agents may also function as clarifying agents. Examples ofsuitable nucleating agents for use in the shell material include silica(e.g., fumed silica), alumnina (e.g., fumed alumina), molybdenumdisulfide, sodium benzoate, talk, graphite, calcium fluoride, clay,sodium phenylphosphinate, zinc phenylphosphinate, sorbitol-based agents,and combinations thereof.

Example of suitable sorbitol-based agents include those commerciallyavailable under the trade designation “MILLARD” from Milliken & Company,Spartanburg, S.C., such as “MILLARD 3988” nucleating agent. Additionalexamples of suitable sorbitol-based agents include those commerciallyavailable under the trade designation “IRGACLEAR” from Ciba SpecialtyChemicals, Basel, Switzerland (subsidiary of BASF SE, Ludwigshafen,Germany), such as “IRGACLEAR XT 386” nucleating agent.

Examples of suitable concentrations of the nucleating agents in theshell material of shell portion 38 range from about 0.01% by weight toabout 20% by weight. In one embodiment, suitable concentrations of thenucleating agents in the shell material range from about 1% by weight toabout 10% by weight. In yet another embodiment, suitable concentrationsof the nucleating agents in the shell material range from about 1% byweight to about 5% by weight.

It some embodiments, the base polymer of the core material may bepolymerized in a manner such that the core material is free orsubstantially free of impurities that promote crystallization. Forexample, the core material is desirably free or substantially free ofpolymerization catalysts or particulate additives that may promotecrystallization, such as providing a polyamide that has been polymerizedas an uncatalyzed hydrolytically-polymerized material.

The above-discussed material combinations for the core and shellmaterials may also be further combined together. For example, the coreand shell materials may include the same or similar base polymers, wherethe core material includes one or more additives to decrease itscrystallization temperature, and where the shell material includes oneor more additives to increase its crystallization temperature.Accordingly, the core and shell materials may include a variety ofcompositional combinations to attain a desired difference incrystallization temperatures.

In the shown embodiment, filament 34 has a cylindrical geometry. Coreportion 36 has an outer diameter referred to as core diameter 36 d, andshell portion 38 has an outer diameter referred to as shell diameter 38d, where shell diameter 38 d also corresponds to the outer diameter offilament 34. The relative dimensions for shell diameter 38 d to corediameter 36 d are desirably selected such that the amount of the shellmaterial that is extruded falls within a balanced range for use insystem 10 (shown in FIG. 1).

The amount of the shell material in filament 34 is desirably high enoughsuch that the extruded roads used to build each layer of 3D model 24(shown in FIG. 1) have sufficient quantities of the shell material(which crystallizes upon deposition in build chamber 12) to resistgravity and the pressures exerted on the extruded roads during theformation of subsequent layers of 3D model 24. On the other end, theamount of the shell material is desirably low enough to preventsubstantial distortions of 3D model 24 upon deposition. The amount ofthe shell material in filament 34 may be determined by dividing theaverage volume of shell portion 38 from the overall average volume offilament 34 (i.e., the sum of the average volumes of core portion 36 andshell portion 38). The average diameters, cross-sectional areas, andvolumes referred to herein are based on average measurements taken for asuitable segment of filament 34 along longitudinal length 40, such as adistance of 6.1 meters (20 feet).

In embodiments in which core diameter 36 d and shell diameter 38 d areeach substantially uniform along longitudinal length 40, measurements ofthe volumes of shell portion 38 and filament 34 may be simplified tofunctions of the respective cross-sectional areas. For cylindricalfilament 34, the cross-sectional areas for core portion 36, shellportion 38, and filament 34 may be determined based on core diameter 36d and shell diameter 38 d.

Examples of suitable average diameters for core diameter 36 d range fromabout 0.76 millimeters (about 0.03 inches) to about 2.5 millimeters(about 0.10 inches). In one embodiment, suitable average diameters forcore diameter 36 d range from about 1.0 millimeter (about 0.04 inches)to about 1.5 millimeters (about 0.06 inches). Examples of suitableaverage diameters for shell diameter 38 d range from about 1.0millimeter (about 0.04 inches) to about 3.0 millimeters (about 0.12inches). In one embodiment, suitable average diameters for shelldiameter 38 d range from about 1.0 millimeter (about 0.04 inches) toabout 1.5 millimeters (about 0.06 inches). In another embodiment,suitable average diameters for shell diameter 38 d range from about 1.5millimeters (about 0.06 inches) to about 2.0 millimeters (about 0.08inches).

Correspondingly, examples of suitable average cross-sectional areas forcore portion 36 range from about 0.5 square millimeters to about 5square millimeters. In one embodiment, suitable average cross-sectionalareas for core portion 36 range from about 0.75 square millimeters toabout 2 square millimeters. Examples of suitable average cross-sectionalareas for filament 34 range from about 0.5 square millimeters to about 8square millimeters. In one embodiment, suitable average cross-sectionalareas for filament 34 range from about 1 square millimeter to about 3square millimeters. In another embodiment, suitable averagecross-sectional areas for filament 34 range from about 1 squaremillimeter to about 2 square millimeters. In yet another embodiment,suitable average cross-sectional areas for filament 34 range from about2 square millimeters to about 3 square millimeters.

The use of cross-sectional areas is also suitable for determining thecross-sectional dimensions of semi-crystalline filaments of the presetdisclosure that have non-cylindrical geometries (e.g., oval,rectangular, triangular, star-shaped, and the like), as discussed below.For example, suitable average cross-sectional areas for the core portionof a non-cylindrical consumable filament of the present disclosure rangefrom about 0.25 square millimeters to about 0.75 square millimeters.Correspondingly, examples of suitable average cross-sectional areas forthe non-cylindrical consumable filament range from about 0.5 squaremillimeters to about 1.5 square millimeters.

Suitable volumes and cross-sectional areas for shell portion 38 may bedetermined based on these above-discussed suitable cross-sectionalareas. Examples of suitable average volumes for shell portion 38 rangefrom about 5% to about 75% of the average volume of filament 34. In oneembodiment, suitable average volumes for shell portion 38 range fromabout 15% to about 65% of the average volume of filament 34. In anotherembodiment, suitable average volumes for shell portion 38 range fromabout 25% to about 55% of the average volume of filament 34.

Correspondingly, in embodiments in which core portion 36 and shellportion 38 are each substantially uniform along longitudinal length 40,examples of suitable average cross-sectional areas for shell portion 38range from about 5% to about 75% of the average cross-sectional area offilament 34. In one embodiment, suitable average cross-sectional areasfor shell portion 38 range from about 15% to about 65% of the averagecross-sectional area of filament 34. In another embodiment, suitableaverage cross-sectional areas for shell portion 38 range from about 25%to about 55% of the average cross-sectional area of filament 34.

As further shown in FIG. 2, shell portion 38 extends entirely aroundcore portion 36 along longitudinal length 40. In alternativeembodiments, shell portion 38 may extend only partially around coreportion 36, such as with a “C” shaped arrangement. In additionalalternative embodiments, shell portion 38 may extend partially or fullyaround core portion 36 in non-contiguous segments along longitudinallength 40. These alternative embodiments are suitable for modifying thefeed mechanics of filament 34 through system 10, and for attainingdesired volume fractions of the shell material.

Filament 34 may be manufactured with a co-extrusion process, where thecore and shell materials may be separately compounded and co-extruded toform filament 34. While core portion 36 and shell portion 38 areillustrated in FIG. 2 as having a defined interface, it is understoodthat the core and shell materials may at least partially interdiffuse atthis interface due to the co-extrusion process. After formation,filament 34 may be wound onto a spool or be otherwise packaged for usewith system 10 (e.g., within supply source 20).

While the consumable, semi-crystalline filaments of the presentdisclosure are discussed herein as having a core portion and one or moreshell portions, the semi-crystalline filaments of the present disclosuremay alternatively include different arrangements of the multiplesemi-crystalline polymeric materials, such that each semi-crystallinefilament includes a first portion that compositionally includes a firstsemi-crystalline polymeric material, and a second portion thatcompositionally includes a second semi-crystalline polymeric materialhaving a higher crystallization temperature than the firstsemi-crystalline polymeric material.

For example, in one embodiment, the semi-crystalline filament may bemanufactured to provide a gradual or step-wise gradient of thesemi-crystalline filament materials between a central axis and an outersurface. In this embodiment, the semi-crystalline filament materials maybe highly interdiffused to provide a gradual interface between a firstportion (e.g., a core potion) and second portion (e.g., a shellportion). At the central axis, the composition of the semi-crystallinefilament desirably includes a first semi-crystalline polymeric material(e.g., a core material), and at the outer surface, the composition ofthe semi-crystalline filament desirably includes only a secondsemi-crystalline polymeric material (e.g., a shell material). Inbetweenthe central axis and the outer surface, the concentration of the secondsemi-crystalline polymeric material may gradually increase in an outwarddirection from the central axis to the outer surface.

FIGS. 3 and 4 respectively illustrate DSC plots of heat flow versustemperature during cooling stages for the shell and core materials offilament 34. As discussed above, the shell material of shell portion 38has a higher crystallization temperature than the core material of coreportion 36. DSC provides a suitable technique for measuring the percentcrystallinities, the crystallization temperatures, and the meltingtemperatures for the core and shell materials, where the DSC plotsreferred to herein are measured pursuant to ASTM D3418-08.

As shown in FIG. 3, after being heated beyond its melting temperatureand allowed to cool, the shell material of shell portion 38 generatesDSC plot 46. In particular, as the measured temperature drops, asindicated by arrow 48, the heat flow remains substantially constantuntil the crystallization onset temperature of the shell material isreached. At this point, the shell material crystallizes and releasesheat, as indicated by exothermic crystallization peak 50. Aftercrystallizing, the shell material then cools down further, as indicatedby arrow 52.

Peak 50 may be used to determine the crystallization temperature of theshell material, where the crystallization temperature of the shellmaterial may be identified by a peak crystallization temperature or aslope-intercept crystallization temperature. As used herein, the term“peak crystallization temperature” refers to a temperature correspondingto a peak point of an exothermic crystallization peak on a DSC plot, andcorresponds to the maximum rate of crystallization for the shellmaterial. For example, as shown in FIG. 3, peak 50 has a peak point 54at temperature T1. Thus, temperature T1 is the peak crystallizationtemperature for the shell material of shell portion 38.

As used herein, the term “slope-intercept crystallization temperature”refers to a temperature corresponding to a point at which the slope ofthe rising curve of an exothermic crystallization peak on a DSC plotintersects with a baseline of the exothermic crystallization peak. Therising curve of an exothermic crystallization peak is based on themeasured heat flow as the material begins to crystallize from the moltenstate. For example, as shown in FIG. 3, peak 50 for the shell materialincludes rising curve 56 and baseline 58, where rising curve 56 has aslope defined by line 60. Line 60 intersects baseline 58 at intersectionpoint 62, which is located at temperature T2. Thus, temperature T2 isthe slope-intercept crystallization temperature for the shell materialof shell portion 38.

Correspondingly, as shown in FIG. 4, after being heated beyond itsmelting temperature and allowed to cool, the core material of coreportion 36 generates DSC plot 64. In particular, as the measuredtemperature drops, as indicated by arrow 66, the heat flow remainssubstantially constant until the crystallization onset temperature ofthe core material is reached. At this point, the core materialcrystallizes and releases heat, as indicated by exothermiccrystallization peak 68. After crystallizing, the core material thencools down further, as indicated by arrow 70.

Peak 68 may be used to determine the crystallization temperature of thecore material in the same manner as peak 50 for the shell material,where the crystallization temperature of the core material may also beidentified by a peak crystallization temperature or a slope-interceptcrystallization temperature. For example, as shown in FIG. 4, peak 68has a peak point 72 at a temperature T3. Thus, temperature T3 is thepeak crystallization temperature for the core material of core portion36. Furthermore, peak 68 for the core material includes rising curve 74and baseline 76, where rising curve 74 has a slope defined by line 78.Line 78 intersects baseline 76 at intersection point 80, which islocated at temperature T4. Thus, temperature T4 is the slope-interceptcrystallization temperature for the core material of core portion 36.

A comparison of FIGS. 3 and 4 show that as the temperatures cool downfrom the molten states of the materials, the shell material begins tocrystallize prior to the crystallization of the core material. As such,at the crystallization temperature of the shell material (e.g.,temperatures T1 and T2), the core material remains in a non-crystallizedor substantially non-crystallized state until the temperature cools downto the crystallization temperature of the core material (e.g.,temperatures T3 and T4). When the crystallization temperature of thecore material is reached, the core material then crystallizes. Thisdifference in crystallization temperatures desirably reducesdistortions, internal stresses, and sagging of the core and shellmaterials when deposited as extruded roads to form layers of 3D model 24(shown in FIG. 1).

Measurements based on peak crystallization temperatures typicallyprovide greater differences between the crystallization temperatures ofthe shell and core materials compared to measurements based onslope-intercept crystallization temperatures. Examples of suitabledifferences in peak crystallization temperatures between the shell andcore materials (e.g., between temperatures T1 and T3) includetemperatures of at least about 2° C. In one embodiment, suitabledifferences in peak crystallization temperatures between the shell andcore materials include temperatures of at least about 5° C. In anotherembodiment, suitable differences in peak crystallization temperaturesbetween the shell and core materials include temperatures of at leastabout 10° C. In yet another embodiment, suitable differences in peakcrystallization temperatures between the shell and core materialsinclude temperatures of at least about 15° C.

Examples of suitable differences in slope-intercept crystallizationtemperatures between the shell and core materials (e.g., betweentemperatures T2 and T4) include temperatures of at least about 3° C. Inone embodiment, suitable differences in slope-intercept crystallizationtemperatures between the shell and core materials include temperaturesof at least about 5° C. In another embodiment, suitable differences inslope-intercept crystallization temperatures between the shell and corematerials include temperatures of at least about 8° C.

In some embodiments, it is desirable to maintain the difference in thecrystallization temperatures at an even greater difference to provideless stringent operating parameters in system 10. For example, suitabledifferences in peak crystallization temperatures between the shell andcore materials include temperatures of at least about 20° C. In oneembodiment, suitable differences in peak crystallization temperaturesbetween the shell and core materials include temperatures of at leastabout 30° C. In another embodiment, suitable differences in peakcrystallization temperatures between the shell and core materialsinclude temperatures of at least about 40° C.

In other embodiments, it is desirable to maintain the difference in thecrystallization temperatures below an upper threshold. Accordingly,examples of suitable differences in peak crystallization temperaturesbetween the shell and core materials also include temperatures less thanabout 25° C. In one embodiment, suitable differences in peakcrystallization temperatures between the shell and core materialsinclude temperatures less than about 20° C. Correspondingly, examples ofsuitable differences in slope-intercept crystallization temperaturesbetween the shell and core materials also include temperatures less thanabout 20° C. In one embodiment, suitable differences in slope-interceptcrystallization temperatures between the shell and core materialsinclude temperatures less than about 15° C.

The DSC plots may also be used to determine the percent crystallinity ofthe shell and core materials, which is known to those skilled in theart. For example, peak 50 (shown in FIG. 3) maybe used to determine theenthalpy of fusion for base polymer of the shell material. The enthalpyof fusion for the base polymer of the shell material may then benormalized to the enthalpy of fusion of a 100% crystalline polymercorresponding to the base polymer of the shell material, to determinethe percent crystallinity of the base polymer in shell portion 38.Similarly, peak 68 (shown in FIG. 4) maybe used to determine theenthalpy of fusion for the base polymer of the core material. Theenthalpy of fusion for the base polymer of the core material may then benormalized to the enthalpy of fusion of a 100% crystalline polymercorresponding to the base polymer of the core material, to determine thepercent crystallinity of the base polymer in core portion 36.

Furthermore, the melting temperatures of the core and shell materialsare desirably the same or similar to allow filament 34 to be readilymelted in a liquefier of extrusion head 18. As such, the core materialand the shell material may be selected to minimize the differences inmelting temperatures. DSC also provides a suitable technique formeasuring the melting temperatures for the core and shell materials,where the melting temperatures may also be identified by peak meltingtemperatures or slope-intercept melting temperatures.

As used herein, the “peak melting temperature” refers to a temperaturecorresponding to a peak point of an endothermic melting peak on a DSCplot (not shown in FIG. 3 or 4). Correspondingly, the “slope-interceptmelting temperature” refers to a temperature corresponding to a point atwhich the slope of the rising curve of an endothermic melting peak on aDSC plot intersects with a baseline of the endothermic melting peak. Therising curve of an endothermic melting peak is based on the measuredheat flow as the material begins to melt from the solid state.

Examples of suitable differences in peak melting temperatures includetemperatures of about 8° C. or less. In one embodiment, suitabledifferences in peak melting temperatures include temperatures of about3° C. or less. Examples of suitable differences in slope-interceptmelting temperatures include temperatures of about 10° C. or less. Inone embodiment, suitable differences in slope-intercept meltingtemperatures include temperatures of about 5° C. or less.

FIG. 5 illustrates a build operation to build 3D model 24 (shown inFIG. 1) from the semi-crystalline polymeric materials of filament 34(shown in FIG. 2). As discussed above, during a build operation withsystem 10 (shown in FIG. 1), filament 34 is fed to extrusion head 18 ina solid state from supply source 20. While passing through extrusionhead 18, filament 34 is heated in a liquefier to a temperature that isgreater than the melting temperatures of the shell and core materials.The molten materials are then deposited onto platen 14 from extrusiontip 82 of extrusion head 18 in a series of extruded roads to form layers84 of 3D model 24. One or more layers of a support material (not shown)may also be deposited below layers 84 to facilitate the removal of 3Dmodel 24 from platen 14.

In the shown example, the extruded roads of the core and shell materialsmay at least partially retain their core/shell cross-sectional profilefrom filament 34. For example, top extruded road 86 includes core region88 of the core material and shell region 90 of the shell material, whereshell region 90 may extend around and encase core region 88. In oneembodiment, at least a portion of the extruded roads at least partiallyretain their core/shell cross-sectional profile from filament 34. In afurther embodiment, substantially all of the extruded roads at leastpartially retain their core/shell cross-sectional profile from filament34.

While not wishing to be bound by theory, it is believed that asubstantially laminar flow of the molten core and shell materialsthrough a liquefier of extrusion head 18 may allow the extruded roads(e.g., road 86) to at least partially retain their core/shell profile.It is understood that interdiffusion of the molten core and shellmaterials may occur at the interface between core region 88 and shellregion 90. As such, the resulting extruded roads (e.g., road 86) mayexhibit a cross-sectional profile that is the same or substantiallysimilar to that of filament 34 (as shown in FIG. 2), may exhibit a blendof the core and shell materials, or may exhibit a cross-sectionalprofile that is a variation between these two profiles (e.g., a profilein which the core and shell materials are partially interdiffused).

It is understood that the extruded roads (e.g., road 86) are typicallyflattened during the build operation due an ironing effect fromextrusion tip 82 (see e.g., FIGS. 17 and 18 below). As such, having across-sectional profile that is the same or substantially similar tothat of the filament does not necessarily mean that the cross-sectionalshapes are the same (e.g., both are circular). Rather, this phrase meansthat the core material remains encased (or at least partially encased)in the shell material.

As discussed above, build chamber 12 is desirably heated to one or moresuitable temperatures to allow the extruded roads to crystallize in twostages. In one embodiment, the envelope of build chamber 12 may beheated and maintained at one or more temperatures that are about equalto, or within a small range above or below, the crystallizationtemperature of the shell material. For example, the envelope of buildchamber 12 may be heated and maintained at one or more temperatures thatare about equal to, or are within about 20° C. above or below, the peakcrystallization temperature of the shell material, since the shellmaterial may begin crystallizing over a temperature range around itspeak crystallization temperature. In this embodiment, the temperature(s)of build chamber 12 are also desirably greater than the crystallizationtemperature of the core material, at least at the upper region of buildchamber 12, adjacent to extrusion head 18.

Upon being deposited into build chamber 12, the molten core and shellmaterials of road 86 cool from the elevated liquefier temperature withinextrusion head 18 to the temperature(s) of build chamber 12. Thisdesirably cools road 86 to or below the crystallization temperature ofthe shell material, but above the crystallization temperature of thecore material, thereby allowing the shell material to at least partiallycrystallize, while preventing the core material from substantiallycrystallizing. While not wishing to be bound by theory, it is believedthat when the shell material solidifies to form shell region 90 ofextruded road 86, the latent heat of transformation emitted from theshell material is at least partly absorbed by the core material, therebyreducing the rate at which core region 88 crystallizes relative to shellregion 90. It is further believed that this provides good interlayerfusing, which results in good interlayer z-bond strengths (i.e., goodinterlayer bonds along the vertical z-axis).

The shell material of core region 90 desirably crystallizes in less timethan is required to build a single layer of 3D model 24, such that theshell material exhibits at least about 30% crystallinity prior to thedeposition of a subsequent layer, and more desirably at least about 50%crystallinity. In comparison, the core material of core region 88desirably crystallizes more slowly such that shrinkage may occur afterthe formation of one or more subsequent layers. For example, the corematerial may exhibit less than about 10% crystallinity prior to thedeposition of a subsequent layer, more desirably less than about 5%crystallinity.

This difference in crystallization rates within build chamber 12, due tothe difference in crystallization temperatures of the core and shellmaterials, allows the shell material to crystallize upon deposition.This allows road 86 to resist gravity and the pressures of subsequentlydeposited layers. While the crystallized portions of shell region 90contract, the non-crystallized core material of core region 88 preventsroad 86 from fully contracting and distorting, which would otherwiseoccur with an extruded road derived from a single semi-crystallinematerial.

In an alternative embodiment, the envelope of build chamber 12 may bemaintained at one or more temperatures that define a temperaturegradient that decreases in a downward direction along the verticalz-axis. For example, the upper region of build chamber 12 may be heatedand maintained at one or more temperatures that are about equal to, orwithin a small range above or below, the crystallization temperature ofthe shell material. The lower region of build chamber 12, however, maybe maintained at one or more lower temperatures. For example, the lowerregion of build chamber 12 may be heated and maintained at one or moretemperatures that are about equal to, or within a small range above orbelow, the crystallization temperature of the core material. As platen14 lowers downward in an incremental manner along the vertical z-axis,the gradual or stepwise cooling may allow the core material to slowlycrystallize over time as subsequent layers are built.

Instead, the above-discussed suitable volume fractions of the shellmaterial provide a balance that allows crystallized shell region 90 tosupport subsequently deposited layers, while also reducing or minimizingthe shrinkage of road 86. As road 86 subsequently cools down below thecrystallization temperature of the core material, the core material maythen gradually crystallize to fully solidify road 86. As such, thistwo-stage crystallization desirably reduces distortions, internalstresses, and sagging of the semi-crystalline polymeric materials whendeposited as extruded roads to form the layers of 3D model 24.

In an alternative embodiment, to the core and shell materials offilament 34 may be switched such that the core material has acrystallization temperature that is greater than a crystallizationtemperature of the shell material. In this embodiment, upon depositionin build chamber 12, the core portion may crystallize prior to the shellportion, such as with an “islands in the sea” geometry with the islandsnucleating and crystallizing prior to the crystallization of the shellmaterial.

FIG. 6 illustrates filament 134, which is another example of a suitableconsumable, semi-crystalline filament of the present disclosure.Filament 134 is similar to filament 34 (shown in FIG. 2), where therespective reference labels are increased by “100”. As shown in FIG. 6,shell portion 138 of filament 134 is a multi-shell portion that includesinner shell 192 and outer shell 194. In this embodiment, inner shell 192and outer shell 194 each desirably includes a semi-crystalline polymericmaterial, which provides further individual tailoring of the desiredcrystallization characteristics.

Suitable materials for each of inner shell 192 and outer shell 194include those discussed above for shell portion 38 (shown in FIG. 2).For example, the semi-crystalline polymeric material of inner shell 192may have a crystallization temperature that is between thecrystallization temperatures of core portion 136 and outer shell 194.This may allow a stair-step crystallization gradient to be achieved inbuild chamber 12 (shown in FIG. 1). Alternatively, inner shell 192 mayinclude a material that restricts or prevents interdiffusion and/orcrystal growth between the materials of core portion 136 and outer shell194. In this alternative embodiment, suitable materials for inner shell192 may include one or more amorphous polymers.

Suitable dimensions for inner shell 192 and outer shell 194 may varydepending on the particular materials used. In some embodiments, thecombined dimensions of inner shell 192 and outer shell 194 may includethe suitable dimensions discussed above for shell portion 38.Accordingly, the consumable materials of the present disclosure mayinclude two or more layers to attain desired crystallization growthcharacteristics for use in building 3D models with layer-based additivemanufacturing techniques.

Additionally, the core portions of the semi-crystalline filaments mayvary from the embodiments discussed above for filaments 34 and 134. Forexample, in some embodiments, the core portions (e.g., core portions 36and 136) may be located off-axis from the central axis of thesemi-crystalline filament. In additional alternative embodiments, thegeometries of the core portions may be non-cylindrical (e.g., oval ,rectangular, triangular, and the like) and/or hollow to modify thecrystallization characteristics of the resulting extruded roads.

For example, as shown in FIG. 7, filament 234 is similar to filament 34(shown in FIG. 2), where the respective reference labels are increasedby “200”. As shown in FIG. 7, filament 234 includes a non-cylindricalcross-sectional geometry with core portion 236 and shell portion 238each having a rectangular cross-sectional geometry. Examples of suitablematerials for core portion 236 and shell portion 238 include thosediscussed above for core portion 36 and shell portion 38 (shown in FIG.2).

Suitable cross-sectional areas include those discussed above. Forexample, suitable average cross-sectional areas for core portion 236range from about 0.25 square millimeters to about 0.75 squaremillimeters. Correspondingly, examples of suitable averagecross-sectional areas for filament 234 range from about 0.5 squaremillimeters to about 1.5 square millimeters. In addition, themultiple-layered shell embodiment of filament 134 (shown in FIG. 6) mayalso be applied to filament 234 to provide a non-cylindrical,semi-crystalline filament having multiple shell layers.

Filaments 34, 134, and 234, shown above, illustrate suitable consumablematerials of the present disclosure that compositionally includemultiple semi-crystalline polymeric materials having differentcrystallization temperatures. In additional embodiments of the presentdisclosure, the consumable materials may compositionally include othercore and shell materials that impart different properties. In theseembodiments, the consumable materials may be used as modeling materialsto build 3D models (e.g., 3D model 24), as support materials to buildsupport structures (e.g., support structure 26), or both, where thedifferent material properties may assist in the build operations withextrusion-based additive manufacturing systems, such as system 10.

For example, FIG. 8 illustrates filament 334, which is an example of asuitable core-shell filament of the present disclosure that is similarto filament 34 (shown in FIG. 2), and where the respective referencelabels are increased by “300”. In this example, core portion 336compositionally includes a first thermoplastic material (i.e., a corematerial), and shell portion 338 compositionally includes a secondthermoplastic material (i.e., a shell material) that is different fromthe first thermoplastic material. The core and shell materials forfilament 334 are also applicable to filament 134 (shown in FIG. 6) andfilament 234 (shown in FIG. 7).

In one embodiment, the shell material of shell portion 338 may be anamorphous or semi-crystalline thermoplastic material selected for itsadhesive and removal properties, and the core material of core portion336 may be an amorphous or semi-crystalline thermoplastic materialselected for other properties, such as thermal properties, tensilestrengths, flexibility, and the like. This embodiment is particularlysuitable for support materials used to build support structures (e.g.,support structure 26). A support material desirably has good adhesion toa respective modeling material, similar thermal properties to themodeling material, and is desirably removable after the 3D model and thesupport structure are built.

For example, filament 334 may be a first core-shell support materialfilament for use with a second core-shell modeling material filamentthat compositionally include multiple semi-crystalline polymericmaterials having different crystallization temperatures. The shellmaterial for shell portion 338 may be a thermoplastic material that isadhesively compatible with a desired modeling material, and that is atleast partially soluble in an aqueous liquid and/or solution (e.g., anaqueous alkaline solution). Examples of suitable thermoplastic materialsfor shell portion 338 in this embodiment include materials commerciallyavailable under the trademarks “SR-10”, “SR-20”, and “SR-30” solublesupport materials from Stratasys, Inc., Eden Prairie, Minn.; and thosedisclosed in Lombardi et al., U.S. Pat. Nos. 6,070,107 and 6,228,923;Priedeman et al., U.S. Pat. Nos. 6,790,403 and 7,754,807; and Hopkins etal., U.S. Patent Application Publication No. 2010/0096072.

Correspondingly, the core material for core portion 336 in thisembodiment may be a thermoplastic material that has a higher tensilestrength than the shell material. Many compositions for water-solublesupport materials are relatively brittle, which can result in filamentfracturing while being fed through system 10. To reduce the brittleness,the core material may be a material having a higher tensile strength,allowing filament 334 to be fed through system 10 without fracturing orbreaking. This increases reliability of filament 334 in system 10.

Additionally, the core material for core portion 336 in this embodimentmay also be selected for thermal compatibility with the modelingmaterial and the operating temperature of build chamber 12. For example,the core material may be selected to have a similar creep relaxationtemperature to the modeling material. Examples of suitable techniquesfor determining creep relaxation temperatures are disclosed inBatchelder et al., U.S. Pat. No. 5,866,058. This allows build chamber 12to may be heated to, and maintained at, one or more temperatures thatare in a window between the solidification temperature and the creeprelaxation temperature of the part material and/or the support material.

Maintaining this temperature window reduces the risk of mechanicallydistorting (e.g., curling) the 3D models and support structures. Inembodiments, in which the modeling material and the core material ofcore portion 336 are each amorphous thermoplastic materials, suitablecreep relaxation temperatures for the core material range from within20° C. of the creep relaxation temperature of the modeling material,more desirably within 10° C., and even more desirably within 5° C.

FIG. 9 illustrates modeling layers 392 of a model material and supportlayers 394, where support layers 394 are formed by extruded roads 396from filament 334 (shown in FIG. 8). As discussed above for filament 34,during a build operation with system 10 (shown in FIG. 1), filament 334may be fed to extrusion head 18 in a solid state. While passing throughextrusion head 18, filament 334 is heated in a liquefier to atemperature that is greater than the melting temperatures of the shelland core materials. The molten materials are then deposited onto platen14 from an extrusion tip of extrusion head 18 in a series of extrudedroads 396 to form layers 394 of a support structure.

In the shown example, extruded roads 396 of the core and shell materialsmay at least partially retain their core/shell cross-sectional profilefrom filament 334. For example, extruded roads 396 each include coreregion 398 of the core material and shell regions 400 of the shellmaterial, where shell regions 400 may extend around and encase coreregion 398. In one embodiment, at least a portion of the extruded roadsat least partially retain their core/shell cross-sectional profile fromfilament 334. In a further embodiment, substantially all of the extrudedroads at least partially retain their core/shell cross-sectional profilefrom filament 334.

The amount of the shell material in filament 334 is desirably highenough such that extruded roads 396 have sufficient quantities of theshell material to adhere to model layers 392. On the other end, the corematerial of core portion 336 desirably constitutes the bulk volume offilament 334. In other words, the cross-sectional area of shell portion338 is desirably lower than the cross-sectional area of core portion336. This allows filament 334 to have thermal properties and strengthsthat are similar to a filament derived entirely from the core material.Accordingly, in some embodiments, core portion 336 may be the same orsubstantially the same composition as the modeling material (or a coreor shell portion of a modeling material filament).

As can be appreciated, the shell material in shell region 400 adheres tothe modeling material of layers 392 due to their adhesivecompatibilities. Additionally, as shown in FIG. 10A, layers 394 may beremoved from layers 392 by exposing layers 394 to a bath containing anaqueous liquid and/or solution (e.g., an aqueous alkaline solution). Asshown in FIG. 10B, this at least partially dissolves the shell material,which removes support layers 394 from model layers 392. In embodimentsin which the core material is not soluble in the bath, this results in amatrix of the core material, which effectively falls away from modellayers 392, as shown in FIG. 10C.

The consumable materials of the present disclosure may include a varietyof different core and shell materials. This allows the modelingmaterials and/or the support materials to be designed for compatibilitywith each other and for use in extrusion-based additive manufacturingsystems, thereby increasing the range of suitable materials for building3D models and support structures.

EXAMPLES

The present disclosure is more particularly described in the followingexamples that are intended as illustrations only, since numerousmodifications and variations within the scope of the present disclosurewill be apparent to those skilled in the art. Unless otherwise noted,all parts, percentages, and ratios reported in the following examplesare on a weight basis, and all reagents used in the examples wereobtained, or are available, from the chemical suppliers described below,or may be synthesized by conventional techniques.

I. Examples 1 and 2

Consumable, semi-crystalline filaments of Examples 1 and 2 werecoextruded in a core and shell arrangement corresponding to filament 34(shown in FIG. 2). The core material of the core portion includednylon-12 polyamide commercially available under the trade designation“GRILAMID L16” from EMS-Grivory, a unit of EMS-CHEMIE North America,Inc., Sumter, S.C. The shell material of the shell portion included ablend of the nylon-12 polyamide and a nucleating agent, which wascommercially available under the trade designation “GRILAMID L16-LM”from EMS-Grivory, a unit of EMS-CHEMIE North America, Inc., Sumter, S.C.The nucleating agent also functioned as a clarifying agent. The shellmaterial was also dyed with a black colorant to visibility distinguishthe core portion from the shell portion.

FIGS. 11 and 12 are photographs of cross-sectional segments of thesemi-crystalline filaments of Examples 1 and 2, respectively. The shellportions of the semi-crystalline filaments are shown with darker shadedues to the colorant dyes. The core portions of the semi-crystallinefilaments are shown with lighter shades.

The semi-crystalline filaments of Examples 1 and 2 were coextruded withvarying feed rates to vary the volume fractions for the shell portions.The filament of Example 1 (shown in FIG. 11) had an average shellportion volume fraction of about 29%, and the filament of Example 2(shown in FIG. 12) had an average shell portion volume fraction of about43%.

FIGS. 13 and 14 are respective DSC plots of the shell and core materialsused to form the filaments of Examples 1 and 2. The DSC plots weremeasured using a differential scanning calorimeter commerciallyavailable under the trade designation “DSC Q2000” from TA Instruments,New Castle, Del., with a nitrogen atmosphere introduced at 50cubic-centimeters/minute, and a heat increase rate of 10° C/minute. Thesample size of the shell material was 5.1 milligrams, and the samplesize of the core material was 5.9 milligrams.

As shown in the bottom plot of FIG. 13, during a heating phase, theshell material generated an endothermic melting peak, from which thepeak melting temperature (about 179° C.) and the slope-intercept meltingtemperature (about 172° C.) were calculated. After melting, the shellmaterial was allowed to cool down, as illustrated in the top plot ofFIG. 13. While cooling down, the shell material generated an exothermiccrystallization peak, from which the peak crystallization temperature(about 162° C.) and the slope-intercept crystallization temperature(about 163° C.) were calculated.

As shown in the bottom plot of FIG. 14, during a heating phase, the corematerial generated an endothermic melting peak, from which the peakmelting temperature (about 180° C.) and the slope-intercept meltingtemperature (about 174° C.) were calculated. After melting, the corematerial was allowed to cool down, as illustrated in the top plot ofFIG. 14. While cooling down, the core material generated an exothermiccrystallization peak, from which the peak crystallization temperature(about 144° C.) and the slope-intercept crystallization temperature(about 153° C.) were calculated.

The calculated results from the DSC plots in FIGS. 13 and 14 provided adifference in the peak melting temperatures of about 1° C., a differencein the slope-intercept melting temperatures of about 2° C., a differencein the peak crystallization temperatures of about 18° C., and adifference in the slope-intercept crystallization temperatures of about10° C. Accordingly, the inclusion of the nucleating agent in the shellmaterial raised the crystallization temperature of the base polymer ofthe shell material (i.e., nylon-12 polyamide) relative to the same basepolymer of the core material. As such, the shell and core materials ofthe semi-crystalline filaments of Examples 1 and 2 were suitable forcrystallization in two stages.

Furthermore, the shell and core materials exhibited similar meltingtemperatures, thereby allowing both the shell and core materials to bereadily melted within a liquefier of an extrusion head. This combinationof a two-stage crystallization with similar melting temperatures rendersthe semi-crystalline filaments of Examples 1 and 2 suitable forextrusion from an extrusion-based layered deposition system to build 3Dmodels that desirably have reduced levels of curling and distortion. Assuch, the 3D models may be built with semi-crystalline polymericmaterials while maintaining dimensional accuracies.

The semi-crystalline filaments of Examples 1 and 2 were then used tobuild 3D models. FIGS. 14 and 16 are photographs of 3D models built withthe exemplary semi-crystalline filaments. The 3D model shown in FIG. 15was a cylinder having a diameter of 6 inches and a height of 8 inches.The 3D model shown in FIG. 16 had a star-shaped geometry. Each 3D modelwas built in an extrusion-based additive manufacturing systemcommercially available from Stratasys, Inc., Eden Prairie, Minn. underthe trade designation “FDM TITAN”. The filaments were melted in anextrusion head liquefier of the system at a set temperature range of260° C. to 300° C., which was greater than the melting temperatures ofthe core and shell materials.

The molten materials were then extruded and deposited into a buildchamber envelope maintained at a temperature range of about 160° C. to180° C. This envelope temperature was close to the peak crystallizationtemperatures of the shell materials of the filaments, and greater thanthe peak crystallization temperatures of the core materials of thefilaments. This allowed the deposited materials to crystallize in twostages, as discussed above, where the shell materials begancrystallizing upon deposition and the core materials crystallized atlater points in time, such as when the 3D models were removed from thebuild chamber.

As shown in FIGS. 15 and 16, the 3D models were built with reducedlevels of curling and distortion, and maintained dimensional accuracies.Furthermore, the 3D models were black in color from the black colorantof the shell material. This shows that the extruded roads of the moltenmaterials retained their core/shell cross-sectional profile, asdiscussed above for core region 88 and shell region 90 of extruded road86 (shown in FIG. 5). The 3D models also exhibited good interlayerz-bond strengths, which is believed to be due to the reduced rate atwhich the core material crystallized relative to the shell material.

As shown in FIGS. 17 and 18, which illustrate multiple extruded roadsformed vertically on top of each other. As can be seen, the extrudedroads retained their core/shell cross-sectional profiles, where, foreach extruded road, the clear core material formed a core region and theblack shell material formed a shell region encasing the core material.

II. Example 3

Consumable, semi-crystalline filaments of Example 3 were also coextrudedin a core and shell arrangement corresponding to filament 34 (shown inFIG. 2). The core material of the core portion included nylon-12polyamide commercially available under the trade designation “GRILAMIDL20” from EMS-Grivory, a unit of EMS-CHEMIE North America, Inc., Sumter,S.C. The shell material of the shell portion included a blend of thenylon-12 polyamide and a nucleating agent, where the nucleating agentalso functioned as a clarifying agent. In this example, the shellmaterial was dyed with an orange colorant. The shell material had apeak-crystallization temperature of about 170° C., and the core materialhad a peak-crystallization temperature of about 142° C.

The semi-crystalline filament of Example 3 was then used to build 3Dmodels. FIGS. 19-22 are photographs of 3D models built with theexemplary semi-crystalline filaments. Each 3D model was built in anextrusion-based additive manufacturing system commercially availablefrom Stratasys, Inc., Eden Prairie, Minn. under the trade designation“FDM TITAN”. The filaments were melted in an extrusion head liquefier ofthe system at a set temperature range of 240° C. to 255° C., which wasgreater than the melting temperatures of the core and shell materials.

The molten materials were then extruded and deposited into a buildchamber envelope maintained at a temperature range of about 170° C. Thisenvelope temperature was about equal to the peak crystallizationtemperature of the shell material of the filament, and greater than thepeak crystallization temperature of the core materials of the filament.This allowed the deposited materials to crystallize in two stages, asdiscussed above, where the shell materials began crystallizing upondeposition and the core materials crystallized at later points in time,such as when the 3D models were removed from the build chamber.

As shown in FIGS. 19-22, these 3D models were also built with reducedlevels of curling and distortion, and maintained dimensional accuracies.Furthermore, the 3D models were orange in color from the orange colorantof the shell material. This shows that the extruded roads of the moltenmaterials retained their core/shell cross-sectional profile, asdiscussed above for core region 88 and shell region 90 of extruded road86 (shown in FIG. 5). The 3D models also exhibited good interlayerz-bond strengths, which, as discussed above, is believed to be due tothe reduced rate at which the core material crystallized relative to theshell material.

Although the present disclosure has been described with reference toseveral embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the disclosure.

1. A three-dimensional object built with an extrusion-based additivemanufacturing system, the three-dimensional object comprising: aplurality of solidified layers each comprising roads formed from aflowable consumable material that exits an extrusion tip of theextrusion-based additive manufacturing system, wherein the flowableconsumable material exiting the extrusion tip comprises a core materialand a shell material that is compositionally different from the corematerial, and wherein the shell material at least partially encases thecore material to provide an interface between the core material and theshell material; and wherein at least a portion of the roads of theplurality of solidified layers comprise core regions of the corematerial and shell regions of the shell material, and wherein the coreregions and the shell regions substantially retain cross-sectionalprofiles corresponding to the interface between the core material andthe shell material of the flowable consumable material.
 2. Thethree-dimensional object of claim 1, wherein the core material and theshell material at least partially interdiffuse at the interface betweenthe core material and the shell material.
 3. The three-dimensionalobject of claim 1, wherein the core material comprises a thermoplasticpolymer.
 4. The three-dimensional object of claim 3, wherein the shellmaterial comprises a colorant.
 5. The three-dimensional object of claim4, wherein the shell material further comprises a second thermoplasticpolymer.
 6. The three-dimensional object of claim 5, wherein thethermoplastic core material comprises a first semi-crystalline polymericmaterial having a first peak crystallization temperature, and whereinthe thermoplastic shell material comprises a second semi-crystallinepolymeric material having a second peak crystallization temperature thatis different than the first peak crystallization temperature.
 7. Thethree-dimensional object of claim 1, wherein substantially all of theroads of the plurality of solidified layers comprise the core regionsand the shell regions that retain cross-sectional profiles correspondingto the interface between the core material and the shell material of theflowable consumable material. 8-20. (canceled)